Paperboard tray



B. J. MILLER PAPERBOARD TRAY Dec. 22, 1964 2 Sheets-Sheet 1 Filed Dec. 10, 62

Dec. 22, 1964 B. J. MILLER PAPERBOARD TRAY Filed Dec. 10, 1962 2 Sheets-Sheet United States Patent Ofifice 3,162,350 Patented Dec. 22, 1964 3,162,350 PAPERBOARD TRAY Bernard J. Miller, Braddock, Pa., assignor to St. Reg1s Paper Company, New York, N.Y., a corporation of New York Filed Dec. 10, 1962, Ser. No. 243,418 2 Claims. (Cl. 22934) This invention relates to trays which may be formed of sheet material such as paperboard, for example rigid or semi-rigid corrugated double-faced kraft fibreboard.

Trays made in accordance with the invention are particularly adaptable, among other possibilities, for use as collapsible or disposable hospital trays, for example for purposes such as carrying food or drinks or for use by doctors and nurses in carrying instruments or other equipment.

The invention provides a construction which may be cut from a single sheet of corrugated paperboard or other inexpensive sheet material, the tray as initially formed being cut to the desired shape and with certain crease or fold lines and weakened lines formed thereon so that the same may be stored in flat condition, whereby even large numbers of the trays require very little space for storage, yet providing a construction which can be conveniently set up into tray form with self-locking rail formations at the perimeterthereof, without the use of tools or additonal materials. The set-up tray will have no exposed rough or cutting edges, yet a very lightweight construction is provided which is easy for infirm patients to handle and which, when the rail formations at the edges thereof are folded into place, will provide a relatively strong and firm structure having adequate weight capacity for its intended purposes, the end rail portions being especially firm and rigid and of a shape adapted easily and firmly to be grasped by the user.

After the tray has been used, if desired the side and end rail formations may readilybe unfolded and flattened out so that the tray may be rolled upon itself for easy disposal in a small space. Alternatively, if desired, the tray may be made of a semi-rigid sheet material of paperboard or other inexpensive fibrous material with surfaces suitably treated to resist moisture and whereby same may be cleaned if desired with a damp cloth or otherwise, permitting the tray to be reused.

In accordance with the invention, the end rail formations which are adapted respectively to be grasped by the two hands of the user in lifting the tray, are preferably formed by folding flap formations, which are integral with the base of the tray, along precreased or weakened fold lines into the shape of tubular formations having a triangular cross-section, for example a cross-section in the shape of a right angle triangle with its right angle at the outer upper corner of the end rail and with its hypotenuse extending from the inner lip of the rail downwardly and outwardly to the base of the rail. Thus the end rails have a cross-section such that the inner upper edges thereof overhang somewhat the base portions of the end rails whereby the user may readily grasp the end rails by placing his fingers on the outer surfaces thereof and with his thumbs in under the inside overhanging portions thereof.

Further in accordance with the invention the side rails of the tray may be formed by flap portions integral with the main part or base of the tray and which are folded upwardly, thence over and downwardly. To secure both the end rail and side rail flap portions in a substantially locked relation to the base or main portion of the tray,

the latter may be formed with slots adapted to be removably engaged by complementary lug portions on the edges of the folded-over flap portions. Also at the corners of the tray, to add to the strength and rigidity of the structure, the flaps may be formed with certain extension portions which serve to bring the end and side rail formations into a firm interengaging and substantially locked relation.

Various further and more specific objects, features and advantages of the invention will appear from the description given below, taken in connection with the accompanying drawings, illustrating by way of example a preferred form of the invention.

In the drawings:

FIG. 1 is a perspective view of a preferred form of tray made in accordance with the invention and indicating the manner in which same may be grasped and carried by the user.

FIG. 2 shows the left hand end portion of a blank form of sheet material in flat condition and as properly shaped and provided with fold lines or weakened lines for formation into the desired tray. The right hand portions of this blank, which are not shown are correspondingly shaped.

FIGS. 3, 4 and 5 are sectional views taken substantially along the lines 3-3, 44 and 5-5 respectively of FIG. 1.

FIG. 6 is a perspective view of one corner portion of the tray with the various flap portions which form the side and end rails thereof shown in partially assembled relation.

Referring to the drawings in further detail, the bottom or main body portion of the tray is indicated at 10 with side rail formations at 11, 12 and end rail formations at 13 and 14.

As shown in FIG. 2, the blank from which such tray is to be made is so cut that the portions which are to provide the side rails 11, 12, will be formed of flaps integral with the base 10 and joined thereto along crease lines as at 15. Along the mid-portion of such flaps, a pair of crease lines is formed as at 16, these crease lines being spaced apart by a distance equal to the desired width of the upper edges 17 of the side rails. Along the outer edges of these flaps, they are cut with lug formations as at lsadapted to cooperate with slots as at 19 cut in the base of the tray along adjacent the fold line 15. Thus each of the flaps which are to form the side rails may be first folded to a position vertical with respect to the base of the tray and then the upper portions of the flap may be folded over inwardly and downwardly about the fold lines 16, while the lugs 18 are inserted into the slots 19, thereby effectively locking the side rail formations in place.

To provide the end rail formations, the base 10 may be formed with integral flaps at each end and each such flap being constituted of three portions as at 20, 21 and 22. The flap portion 20 joins the base along crease line 23 and joins the flap portion 21 along a crease line or perforated weakened line as at 24. Flap portion 21 in turn joins flap portion 22 along another crease or weakened line of perforations 25. The parallel weakened lines 24- and 25 are spaced apart by a distance equal to the width of the flap portion 21, which in turn, as will be apparent, is equal to the desired Width of the upper surface of the completed end rail. Flap portion 22 is provided with lug portions as at 26 adapted to be engaged in complementary slit openings as at 27, which preferably are located along the crease line 23, and partially extending into the base portion 10 and partially into the adjacent parts of the flap portion 20. Thus when it is desired to fold the end flaps into formations for providing the end rails, the flap portions 20 are flexed up to vertical positions, then each flap portion 21 may be flexed inwardly to a horizontal position while the flap portion 22 is folded downwardly and outa v 3 a v wardly so, as to brin'g the lugs 26 into position to extend diagonally downwardly and outwardly through the slits 27, as best shown in FIG. 3.

To provide means for efiectively retaining the rail corner portions in their relative desired'positions and inra substantially locked relation, the flap portions at each end may be formed with extensions 'asat which-are adapted to be folded over and embraced between the folded portions of the-side rail flapswhen the tray 'is in set-up or" assembled condition; The manner in which these flap extensions 30 maybe folded into place to be engaged by the side rail flap portions is best indicated in extensions '30may be joined tothe'flap portion 20 along crease lines as at 31 and thus the area of juncture serves to complete and close the, rail cornerformation While at the same time the 'flap' extension portionsfii may extend far enough into embraced relation by the side rail flap portions so that the end rail flap'iportions 20 will be se' curelyheld in, proper'position, thereby insuring that the remaining end rail flapportions 21 and 2 2 will also be held in'position by reason .of the-lug and'slot formations 26 and 27,"as shown in' FIG. 3. Q

1 As best indicated in FIGS. '3 and 6, in case thetray is formed of corrugated paperboard or the like, theco'rrugations may-preferably extend in a'dire'c'tionso as to run longitudinally 'of' the end'rail'fiap portions 20,21 and t I edges along a first handle flap fold line, said first handle flap fold line having handle fiap lug slots formed therein, each said second handle flap portion being integral with and interconnecting said first and third handle flap por- "tions along secondand third'handle flap fold lines respectively, said second handle flap portions being of substantially the same Width as said first handle-flap portions, the outer edge of said third handle flap portion having protruding'lugstthereon at locations corresponding to said handle .flaptlug' slots, said handle flap-portions being of relative width to form a right triangular cross sectional configuration when said first and second handle flap portions arebent at right angles about said first and second fold lines and said lugsare inserted into said lug slots, the width of .suchhandle flap portions further being such =as tofo'rm said triangular configuration of a size which may be'conveniently grasped by full encirclement with the thumb andfingers of -a usershand, tab flaps extending from the .ends o'f said first handle flaps, first and second side rail'fiap portions extending longitudinally, along each opposite side edge of said-main baseportion and first side rail flap portions being integral with and connected to said main baseportion alongfa first side rail fold line having lug slots formed therealong, each said'second side rail flap portion being integral vwith andconnected along the outer'edge of a first side rail flap portion along a second side rail fold line, thei'outeryedge of each said second side rail fiapportions having lugs protruding there- I from tatQlo cation's corresponding to the lug "slots formed 22, 'thereby-'contributingto the rigidity of the end rails when foldedinto" position. 7

Although a certainparticular ernbodirrient of the in vention is herein disclosed for purposes ofeexplanation, further modifications thereof, after study of this specifithe invention" pertains. Reference should'accordinglybe j ad to 'the'appended claims-in determiningthe scope of the invention.

'Wha't'is elaimedand desired to bevsecured 'by'Letters siibstantially rectangular configuration, an 'end flap handle construction formed along each'opp'osite'end edge of said frnain base portion, said, end' flap; handle construction comjarisin'g first, second and third handle flap portions which "cation, will be apparentto those skilled in the art to which, I

extend'longitudinally of 'sa'id end edges, 'ea chsaid'first handle'fiap portions being integral with one of said end,

along said fiistside lrail' fold lines, the width of'each side rail flap portions 'being substantially equal to the width of said tab flaps so. as to fold about :and snugly'enc'lose said tab portions when said i endfflap portions are folded into said "triangular cross sectional configuration ZJApaperboardblank as defined in claim 1 wherein fsaid'blank is ofra double face corrugated paperboard material formed with corrugations: extending longitudinally ofsaid handle-flaps.- I r 371 References Cited in the file=of patent V UNITED STATESfPATENTS -,"3 ,0'14',635 Mairs et al. Dec.26, 1-961 FOREIGN PATENTS 4 664,852 Great Britain TJan. 16, 19.52 7 664,853 Great Britain J'an..16, 1952 686,240 Gre at-Britain Jan. 21, '1953 

1. A PAPERBOARD BLANK ADAPTED TO BE FOLDED INTO A RIGID TRAY, SAID BLANK COMPRISING A MAIN BASE PORTION OF SUBSTANTIALLY RECTANGULAR CONFIGURATION, AN END FLAP HANDLE CONSTRUCTION FORMED ALONG EACH OPPOSITE END EDGE OF SAID MAIN BASE PORTION, SAID END FLAP HANDLE CONSTRUCTION COMPRISING FIRST, SECOND AND THIRD HANDLE FLAP PORTIONS WHICH EXTEND LONGITUDINALLY OF SAID END EDGES, EACH SAID FIRST HANDLE FLAP PORTIONS BEING INTEGRAL WITH ONE OF SAID END EDGES ALONG A FIRST HANDLE FLAP FOLD LINE, SAID FIRST HANDLE FLAP FOLD LINE HAVING HANDLE FLAP LUG SLOTS FORMED THEREIN, EACH SAID SECOND HANDLE FLAP PORTION BEING INTEGRAL WITH AND INTERCONNECTING SAID FIRST AND THIRD HANDLE FLAP PORTIONS ALONG SECOND AND THIRD HANDLE FLAP FOLD LINES RESPECTIVELY, SAID SECOND HANDLE FLAP PORTIONS BEING OF SUBSTANTIALLY THE SAME WIDTH AS SAID FIRST HANDLE FLAP PORTIONS, THE OUTER EDGE OF SAID THIRD HANDLE FLAP PORTION HAVING PROTRUDING LUGS THEREON AT LOCATIONS CORRESPONDING TO SAID HANDLE FLAP LUG SLOTS, SAID HANDLE FLAP PORTIONS BEING OF RELATIVE WIDTH TO FORM A RIGHT TRIANGULAR CROSS SECTIONAL CONFIGURATION WHEN SAID FIRST AND SECOND HANDLE FLAP PORTIONS ARE BENT AT RIGHT ANGLES ABOUT SAID FIRST AND SECOND FOLD LINES AND SAID LUGS ARE INSERTED INTO SAID LUG SLOTS, THE WIDTH OF SUCH HANDLE FLAP PORTIONS FURTHER BEING SUCH AS TO FORM SAID TRIANGULAR CONFIGURATION OF A SIZE WHICH MAY BE CONVENIENTLY GRASPED BY FULL ENCIRCLEMENT WITH THE THUMB AND FINGERS OF A USER''S HAND, TAB FLAPS EXTENDING FROM THE ENDS OF SAID FIRST HANDLE FLAPS, FIRST AND SECOND SIDE RAIL FLAP PORTIONS EXTENDING LONGITUDINALLY ALONG EACH OPPOSITE SIDE EDGE OF SAID MAIN BASE PORTION AND FIRST SIDE RAIL FLAP PORTIONS BEING INTEGRAL WITH AND CONNECTED TO SAID MAIN BASE PORTION ALONG A FIRST SIDE RAIL FOLD LINE HAVING LUG SLOTS FORMED THEREALONG, EACH SAID SECOND SIDE RAIL FLAP PORTION BEING INTEGRAL WITH AND CONNECTED ALONG THE OUTER EDGE OF A FIRST SIDE RAIL FLAP PORTION ALONG A SECOND SIDE RAIL FOLD LINE, THE OUTER EDGE OF EACH SAID SECOND SIDE RAIL FLAP PORTIONS HAVING LUGS PROTRUDING THEREFROM AT LOCATIONS CORRESPONDING TO THE LUG SLOTS FORMED ALONG SAID FIRST SIDE RAIL FOLD LINES, THE WIDTH OF EACH SIDE RAIL FLAP PORTIONS BEING SUBSTANTIALLY EQUAL TO THE WIDTH OF SAID TAB FLAPS SO AS TO FOLD ABOUT AND SNUGLY ENCLOSE SAID TAB PORTIONS WHEN SAID END FLAP PORTIONS ARE FOLDED INTO SAID TRIANGULAR CROSS SECTIONAL CONFIGURATION. 